KR101223375B1 - Anti-fog refrigeration door and method of making the same - Google Patents

Abstract

The refrigeration door herein without energy consumption provides a method of controlling condensation even when the door of the refrigeration unit is opened by providing thermal insulation to a door made of glass panel with a low emissivity coating. The door includes an insulated glass unit consisting of a door frame housing and inner, middle and outer glass sheets. The first sealant assembly disposed around the inner and middle glass sheets forms a first chamber between the inner and middle glass sheets. The second sealant assembly disposed around the middle and outer glass sheets forms a second chamber between the middle and outer glass sheets. Gases such as krypton, air or argon are received in the first and second chambers. The outer glass sheet and the inner glass sheet each have an unexposed surface facing the intermediate glass sheet. A low emissivity coating is placed on the non-exposed surfaces of the inner and outer glass sheets, so that, without the supply of electricity to heat the door, the glass door as a whole has a U value that prevents the formation of condensate on the outer surface of the outer glass sheet, It also provides the desired vaporization rate of the condensate from the inner side of the inner sheet of the glass door. An anti-fog or anti-frost coating may be included on one surface of the glass sheets.

Refrigerator, door, anti-fog, anti-frost

Description

Anti-fog refrigerated door and its manufacturing method {ANTI-FOG REFRIGERATION DOOR AND METHOD OF MAKING THE SAME}

FIELD OF THE INVENTION The present invention relates generally to refrigeration doors, insulated glass units and refrigeration systems, in particular anti-fog or energy-free, which provides condensation control, thermal insulation and the desired amount of visible transmission. An anti-frost refrigerated door. More specifically, the refrigerated door of the present invention is achieved through the application of a low-emissivity coating, by applying an anti-fog / frost resistant coating or film, without electrical heating of the door. As used herein, the term "refrigerated door" means a door for use in refrigerators, refrigerators and similar devices and cabinets. In addition, in this specification, the term "no energy consumption" (as in a refrigeration door without energy consumption) means that no electricity is supplied to the glass to heat the glass. "Anti-fog" and "anti-frost" means a coating or film that reduces or eliminates the clearing time of refrigerated doors, insulating glass units (IGUs) or other devices described herein.

All US patents and US patent application publications mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control.

Refrigerated doors used in commercially available freezers, refrigerators and the like are usually made of glass and allow the buyer to see the product placed therein without opening the door. However, if condensation forms on the glass (sometimes referred to as "fog"), it is not desirable for buyers and shop owners or retailers as the buyer cannot see through the door to identify the product inside. The formation of frost causes similar problems.

The cooler inside of the freezer or refrigerator causes water vapor to condense on the outside of the glass refrigeration door because the outside surface temperature of the glass is lower than the ambient temperature inside the store. When the temperature of the glass surface is lower than the dew point of the air in the store, water vapor condenses on the glass surface. In addition, when the door is opened in a wet environment, the innermost sheet of glass, which forms the interior of the door, may also be instantaneously exposed to the ambient air of the store, where condensation may form inside the door. Condensation inside the glass door also occurs because the temperature inside the glass door is lower than the dew point of the ambient air of the store to which the door is exposed.

As pointed out earlier, condensation on glass doors, which can be frosted, prevents buyers from seeing the product being sold through the glass door. As a result, if there is condensation or frost on the glass door, it must be unwelcome to have the buyer open the refrigerated door to verify its contents. Not only is it undesirable for retailers to open all refrigerated doors to the buyer's point of view, as it is not only tedious and time consuming, but also significantly increases the energy consumption of the retailer's freezers and refrigerators, resulting in higher energy costs for the retailer.

There are several industry-specific limits for the performance that refrigerated doors must follow. In the United States, in many industries, chillers prevent external condensation when used in an environment with an external temperature of 80 degrees Fahrenheit (80F), an external relative humidity of 60%, and an internal temperature of -40 degrees Fahrenheit (-40F). It requires a door (not a refrigerator door). The requirements in other countries are different.

As is well known in the art, typical refrigerated doors consist of an insulating glass unit (IGU) housed in a door frame. The IGU of a refrigerated door usually consists of two or three glass sheets whose peripheral edges are sealed by sealant assemblies, commonly referred to as edge seals. In an IGU consisting of three glass sheets, two insulating chambers are formed between three glasses. In an IGU consisting of two glass sheets, a single insulating chamber is formed. Typically, the refrigerator IGU consists of two glass sheets, while the refrigerator IGU is arranged three glass sheets. Once sealed, the chamber is often filled with an inert gas such as argon, krypton, or other suitable gas to improve the thermal performance of the IGU.

Most conventional approaches to preventing or reducing condensation in refrigerated doors involve the supply of energy to the door by including a conductive coating on one or more glass surfaces of the IGU for electrical heating of the glass. The purpose of heating the glass is to keep the temperature of the glass higher than the dew point of the milder ambient air in the store. Heating the glass above the dew point prevents the formation of unwanted condensate and frost on the glass of the door, thereby ensuring a clear view of the interior of the refrigerating compartment.

In doors consisting of three-paned IGUs, one or two unexposed surfaces of glass sheet are coated with a conductive material. The conductive coating is connected to the power source by two bus bars or other electrical connectors mounted at opposite corners of the glass. As the current passes through the coating, the coating is heated to provide a surface where condensation does not occur by heating the glass sheet. The coating on the IGU of the refrigerated door is usually provided on the unexposed side of the outermost glass sheet. However, since the condensate is sometimes formed on the inner surface of the inner glass sheet, a coating for heating may also be applied to the unexposed surface of the innermost glass sheet to prevent condensation.

There are a number of drawbacks and problems with refrigerated doors that heat in this conventional manner of the prior art. First, heating of the door leads to additional energy costs that exceed the energy costs of the cooling system. In commercially available standard size freezers, the additional cost of heating the freezer door is significant, based on current electricity usage fees, which can be over $ 100 per year for each freezer. Considering the use of multiple freezers in many stores, even some supermarkets and other grocery retailers use hundreds of freezers, and the cumulative costs associated with heating such freezer doors are enormous.

Second, excess heat from conventional heated refrigeration doors will be transferred to the refrigeration compartments, placing additional strain on the cooling system, which in turn will result in much higher energy costs. Third, if the power supplied to the door for heating is too low, turned off, or shut off due to a power outage, condensate and / or frost will form on the glass. If the power loss is too large, unnecessary extra energy costs will be incurred. In order to reduce the occurrence of this problem, such heated glass doors often require sophisticated control of the door heating system. In order to achieve the necessary and sophisticated control of the door heating system, an electrical control system is required, which results in an increase in the design and manufacturing costs, as well as a significant increase in operating and maintenance costs.

Fourth, such electrically heated glass doors present a safety threat to buyers and a potential risk of reliability and exposure to retailers and refrigeration system manufacturers. The voltage provided to the coating of the glass door is usually 115 volts AC. The shopping cart used by the shopper in the store is heavy and made of metal. If the shopping cart hits and breaks the glass door, electricity flows to the buyer through the cart, which can result in serious injury or even death.

U.S. Patents 5,852,284 and 6,148,563 disclose the application of a voltage to glass coated with a conductive coating, which may be a low emissivity coating, which controls the formation of condensate on the outer surface of the glass door. Conductive coatings, such as low emissivity coatings, provide resistance to heat generation with respect to electrical forces, while providing desirable thermal properties. However, the refrigerated doors disclosed through these patents suffer from all the aforementioned disadvantages and problems associated with electrically heated refrigerated doors. Glass units, refrigeration units and the like are also disclosed in US Pat. Nos. 6,367,223, 6,606,832, and 6,606,833. As noted, these and other US patents and patent applications are incorporated herein by reference in their entirety.

In addition to being used for conduction, such low emissivity coatings have been used as another means for the removal of condensate on refrigerated doors. Specifically, the method of increasing the insulating value (“R value”) of the glass and the method of reducing the heat loss from the cold compartment is to provide a low emissivity (low E) coating on the glass. The low E coating is a layer of metal or metal oxide that is microscopically thin and applied to the glass surface to reduce emissivity by suppressing radiant heat flow through the glass. Emissivity refers to the emissivity emitted by a blackbody or surface and the theoretical emissivity predicted by Planck's law. The term emissivity is used to mean an emissivity value measured in the infrared region according to the American Society for Testing and Materials (ASTM). Emissivity is measured using a radiometric measurement and reported as hemisphere emissivity and normal emissivity. Emissivity is expressed as a percentage of long wavelength infrared radiation emitted by the coating. Lower emissivity means less heat is transferred through the glass. As a result, the emissivity of the glass or IGU sheet has a strong influence not only on the insulation value of the glass or IGU but also on the thermal conductivity (“U value”) of the glass or IGU. U value of glass or an IGU sheet is the inverse of the R value.

In multi-window IGUs, the emissivity of an IGU combined with the emissivity of several glass sheets forming the IGU can be estimated by multiplying the emissivity of all glass sheets together. For example, the total emissivity of a two piece IGU with an emissivity of 0.5 for each glass sheet would be 0.5 times or 0.5 of 0.5.

While low E coatings provided in IGUs are used for refrigerated doors with and without electric heated doors, such coatings and IGUs provide a wide range of temperatures and environments in which such refrigerated doors are used without the supply of electricity to heat them. There is no ability to control condensation and provide the required thermal insulation. More specifically, despite the use of such a low E coating, unheated refrigeration doors have not been able to control condensation when the internal temperature of the refrigeration compartment is used substantially below or below freezing point.

Furthermore, there are limitations to typical anti-fog / frost resistant coatings, films and the like and methods of providing them. For example, the film still appears cloudy and allows the creation of water droplets that blur the field of view. In addition, anti-fog properties are often lost after simple water soaks or repeated washing operations. Furthermore, known anti-fogging products that function to absorb condensate may not operate under saturated and very wet conditions, at least in the state of high moisture absorption. In addition, these products are easily scratched and dirty and do not have sufficient resistance or resistance to common solvents. Moreover, common coating problems such as drips, runs, trapped dust and chemical crazing can occur in typical antifog products.

Thus, despite effective antifogging and anti-frosting products such as electrically refrigerated doors and films and coatings that are electrically heated and low emissivity coated, (1) provide control and thermal insulation of essential condensate under a wide range of temperatures and environments, ( 2) avoiding unnecessary energy costs and excessive burdens on the cooling system by (3) eliminating the need to provide power to heat the door with the desired visible permeability, and (4) avoiding costly complex electrical control systems. Minimizes design, manufacturing, operation and maintenance costs, and (5) does not pose a threat to safety to buyers, does not pose a potential risk of reliability and exposure to retailers, and overcomes the aforementioned problems. There is a need for refrigerated doors to reduce or reduce.

It is an object of the present invention to overcome the drawbacks of the prior art described above by providing a refrigeration door that is energy consuming free of condensate control, thermal insulation and as desired visible permeability.

It is a further object of the present invention to provide a refrigerated door that does not use electrical energy to remove condensate on the glass.

It is a further object of the present invention to provide a refrigerated door that controls condensation and does not transfer significant heat into the interior of the freezer or refrigerator, which does not burden the cooling system further and does not increase energy costs.

Another object of the present invention is to provide condensation control that is simpler to manufacture, operate and maintain and more economical than conventional refrigerated doors and systems.

It is a further object of the present invention to provide a refrigerated door that involves condensation control which is simpler in design, operation and maintenance.

It is still another object of the present invention to provide a method of manufacturing a refrigerated door that involves condensation control without using electricity for heating the glass to control the condensation.

Another object of the present invention is to provide a refrigerated door having an emissivity of less than 0.04.

Another object of the present invention is to provide a refrigerated door having an emissivity of about 0.0025.

Another object of the invention is to provide a refrigerated door with a U value of less than 0.2 BTU / hr-sq ft-F.

Another object of the present invention is to provide a refrigerated door having a U value of about 0.16 BTU / hr-sq ft-F.

It is yet another object of the present invention to provide a refrigerated door with additional anti-fog and anti-frosting properties that reduce cleaning time to zero or near zero.

Additional purposes include anti-fog or anti-frost coatings or films used in refrigerated doors, refrigeration systems and IGUs comprising such films on the substrate surface.

The present invention achieves these objects, in particular through a refrigeration door and its manufacturing method which are energy-free. In one aspect, the present invention consists of a door frame for receiving an insulated glass unit composed of inner, middle and outer glass sheets. The first sealant assembly disposed around the inner and middle glass sheets forms a first chamber between the inner and middle glass sheets. The second sealant assembly disposed around the middle and outer glass sheets forms a second chamber between the middle and outer glass sheets. Gases such as krypton, air or argon are contained in the first and second chambers. The outer glass sheet and the inner glass sheet have an unexposed surface facing the intermediate glass sheet. The low emissivity coating is disposed on the non-exposed surfaces of the inner and outer glass sheets, providing the desired amount of vaporization of the desired condensate from the inside of the inner sheet of the glass door without the use of electricity to heat the door. As a whole, it has a U value that prevents the formation of condensate on the outer surface of the outer sheet of the glass door. The anti-fogging / anti-frost coating or film is disposed on the surface of one of the glass sheets, preferably on the exposed surface of the inner sheet.

In one aspect, the present invention also provides a novel anti-fog / anti-frost coating.

Anti-fog / anti-frost coatings are useful in a variety of applications, such as insulated glass units with multiple windows, refrigeration and freezer doors for refrigeration and freezer display cases, automotive mirrors, especially exterior mirrors, saunas, steam rooms, shower doors, ticket offices Windows, bathroom windows, bathroom mirrors, external coolers and freezers exposed to high humidity or rain, and other applications requiring anti-fog / frost-resistant coatings or films. Thus, the anti-fog / frost-resistant coating of the present invention is preferably used in connection with refrigeration and freezer doors that are energy consuming, but is also well suited for a variety of other applications, including energy braking doors such as electrically heated doors. .

Hereinafter, the structure and operation of various embodiments of the present invention, as well as additional functions and advantages of the present invention, will be described in detail with reference to the accompanying drawings.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various embodiments of the invention, and together with the description of the invention, illustrate the principles of the invention to enable those skilled in the art to make and use the invention. To make it possible. In the drawings, like numerals refer to the same or functionally similar elements.

By considering the following embodiments in conjunction with the accompanying drawings, the present invention and the accompanying advantages will be more fully understood.

1 is a refrigeration system showing one embodiment according to the present invention.

2 shows a refrigerated door according to the invention.

3 shows a partial cross-sectional view of a refrigerating door according to the invention.

4 shows a partial cross-sectional view of a refrigerating door according to the invention.

In the following description, for purposes of explanation and not limitation, specific details are provided to aid the understanding of the present invention and include specific coatings, coating procedures, sheet and film thicknesses, seal assemblies, number of sheets, sheet spacing, and Door assembly method. However, it will be apparent to those skilled in the art that the present invention may be applied to other embodiments that depart from these specific details. Detailed descriptions of well-known coatings, coating procedures, sealant assemblies, and door assembly methods have been omitted in order not to obscure the description of the present invention. For the purposes of this description of the invention, terms such as outside, inside, outside and inside are, as will be apparent from the drawings, described in terms of the interior of the refrigerator or refrigerator compartment.

Through tests such as computer modeling, the U value of about 0.2 BTU / hr-sq ft-F (heat through glass) is necessary for the refrigerator door to prevent condensation on the outside of the glass under the above-mentioned US industry performance requirements. Conductivity). However, as discussed, when the door is opened, condensation will form on the inside of the inner surface of the glass sheet of the door because the temperature of the inner surface of the sheet is lower than the dew point of the ambient air of the moister shop where the surface is exposed. Can be. However, once the door is closed, the condensate will disappear as the moisture vaporizes into the freezer or refrigerator compartment.

While condensate is present inside the door, the contents of the freezer or refrigerator are not visible through the door. As a result, the rate of vaporization (called "wash time"), which determines the length of time the condensate is present, is an important design criterion. The more heat transferred through the glass door to the inner surface of the glass door, the faster the condensate inside the door will vaporize. However, increasing heat transfer through the door also increases the energy cost of the cooling system. As a result, the optimum U value of the glass door is determined by the temperature difference between the inside and the outside, the thickness of the glass, the spacing, the gas used in the chamber of the IGU, the number of sheets, the material of the spacer, the ambient humidity, the absorption of the coating in the far infrared spectrum. It will be derived from a number of factors including the count and the desired time for vaporizing the condensate. In addition, the costs, energy costs, and other factors associated with the selected components (ie, gas, sealant assembly, glass, etc.) are also design considerations. The preferred embodiment described below is 0.16 BTU / hr- which prevents condensation outside the door while allowing sufficient heat to penetrate through the door from the surrounding external environment in order to vaporize within a suitable time to allow condensation to occur inside the door. Provides the U value of sq ft-F. Some refrigeration system manufacturers require vaporization in minutes and others require vaporization in one minute. In alternative embodiments, the U value will be substantially less than or equal to 0.16 BTU / hr-sq ft-F. The time required for the vaporization of the condensate depends on the amount of time the door is opened, the humidity of the store, the temperature of the compartment in the refrigeration system, the contents of the refrigeration system, the heat transferred through the door (which depends on the U value) and other factors. Change accordingly.

In an embodiment of the invention, as shown in FIG. 1, the refrigeration system 5 comprises a plurality of transparent refrigeration doors 10 each with a handle 11. As will be discussed in more detail below, each refrigerated door 10 includes an IGU 50 mounted to a frame 55. The interior of the refrigeration system includes a plurality of sleeves 6 for holding goods viewed through the door. 2, the refrigerating door 10 of this embodiment is mounted in the opening of a refrigerating system through the hinge which makes a door open outward.

As discussed above, the refrigeration door 10 includes an IGU 50 housed in the frame 55. As shown in FIG. 3, the IGU 50 is composed of an outer glass sheet 60, an intermediate glass sheet 65, and an inner glass sheet 70. The IGU 50 is housed in the frame 55 and also extends between the inner surface 62 of the outer glass sheet 60 and the outer surface of the intermediate glass sheet 65 and has a substantially sealed insulated outer chamber ( A first sealant assembly 90 forming 92. Similarly, the second sealant assembly 95 extends between the outer surface 72 of the inner glass sheet 70 and the inner surface of the intermediate glass sheet 65 and forms a substantially sealed insulated inner chamber 94. do.

The outer surface 61 of the outer glass sheet 60 is disposed adjacent to the outer peripheral environment 7. In other words, the outer surface 61 of the outer sheet 60 is exposed to the environment in which the refrigerator or freezer is placed. The inner surface 62 of the outer sheet 60 forms part of the outer chamber 92 and is exposed to the outer chamber 92.

In the example of the present preferred embodiment, the outer sheet 60 is tempered 1/8 inch thick, and the inner surface 62 of the outer sheet 60 is coated with a low emissivity coating 63. Specifically, in this embodiment, the low E coating is a sputter coated low E coating comprising ultrahard titania as the base layer to ensure high levels of thermal performance and visible high light transmittance. to be. This particular sputter coated glass is strengthened after coating to provide high visible inertial light transmission without high levels of color tinting. The outer surface 61 of the outer sheet 60 is not coated. In this embodiment, the outer sheet 60 is 1/8 inch thick, manufactured by AFG Industries, Inc., Kingsport, Tennessee, for example, with a low E coating that provides a permeability of 0.05. It can be (but not limited to) a Comfort Ti-PS glass sheet. As is well known in the art, the Comfort Ti-PS is cut to size, reinforced and edged prior to being integrated into the IGU 50. The low E coating referred to herein may be any suitable low E coating, including, but not limited to, sputter coated and pyrolytic coated low E coatings, although not limited to the above specifically named products.

The intermediate glass sheet 65 is disposed between the outer glass sheet 60 and the inner sheet 70 to form part of the outer chamber 92 and the inner chamber 94. The intermediate sheet 65 is an 1/8 inch thick, uncoated toughened glass sheet, spaced 1/2 inch from the outer sheet 60 and the inner sheet 70.

The inner glass sheet 70 is disposed adjacent to the interior of the freezer or refrigeration compartment 9, the inner surface 71 of which is exposed into the interior of the compartment 9. The outer surface 72 of the inner sheet 70 forms part of the inner chamber 94 and is exposed to the inner chamber 94. The outer surface 72 of the inner glass sheet 70 is also coated with a low emissivity coating 73. In this embodiment, the low emissivity coating 73 on the outer surface 72 of the inner sheet 70 is the same as the coating 63 of the inner surface 62 of the outer sheet 60 described above. In a preferred embodiment, the inner surface 71 is provided with an anti-fog or anti-frost coating or film, whereby the cleaning time in operation of the unit is considerably, preferably actually zero (ie no visible fogging occurs). A) is reduced.

Preferred anti-fog coatings or films include those known in the art, such as Vistex® and Visgard® from Film Specialities. Such films may include optical adhesive on their back side for installation. For example, Vistex includes a polymer cured on a clear polyester film having an optically clear adhesive on the backside thereof. Vistex and Visgard® can be purchased on plastic films or as liquids. The film removes fog at all temperature and humidity conditions. Moreover, even if the refrigerator or freezer door is tilted by restock or the like and is opened for a relatively long time, the formation of fog and condensate is prevented. By absorbing condensates, these products do not lose their antifogging properties even after simple water uptake or repeated washings, and the coating does not saturate or fail even under very wet conditions. Since the antifogging film used in the present invention is hydrophilic, moisture is spread out invisibly and broadly on the surface of the coating, rather than forming droplets to blur the field of view. Furthermore, the preferred film is scratch resistant and includes an acrylic adhesive on its back side. This adhesive is typically in the form used for solar control films and allows the film to be used on flat or cylindrical surfaces. The adhesion system can be optically clear, pressure sensitive or detackified pressure sensitive. Films of various thicknesses may be used and those skilled in the art will be able to readily determine the appropriate thickness depending on the desired application. Preferred thickness is 4 mils. The film can be mounted to the glass surface using a squeegee.

Preferred films are permanent anti-fog or anti-frost films based on hydrophilic polymer technology. The anti-fog / anti-frost coating serves by reducing the surface tension of the water causing the sheet out of the condensate, thereby removing the fog under all temperature and humidity conditions. Preferred coatings suffer significantly higher usage than most untreated plastics. When exposed to moisture, minor surface scratches on the antifog film will actually heal itself. Furthermore, preferred coatings exhibit significant levels of chemical resistance and will also resist solvents such as isopropyl alcohol, toluene or acetone, and will protect the substrate from penetration of the solvent. If necessary, ordinary glass cleaners may be used.

Preferred films are insoluble in water and, unlike other anti-fog coatings of the prior art, will not stain or dissociate when wet. Since preferred films are cured under controlled conditions, conventional coating problems such as drips, runs, dust capture and chemical crazing are eliminated. Furthermore, the film has a measure of scratch resistance and shatter resistance to the glass provided with the coating. The adhesive will bind to glass or any plastic, even hard scratched hard surfaces.

Along with some known anti-fog and frost-proof films / coatings suitable for use in embodiments of the present invention, prior to the application of the anti-fog or frost-proof film, a cured primer is provided on the glass. Typical coatings, as noted above, known Visgard® available from Film Specialities Inc., include the "Part A": "Part B" chemicals in a mixing ratio of 100: 40. Visgard® Part A ingredients include diacetone alcohol (46%), N-methyl pyrrolidone (4%), t-butanol (4%), cyclohexane (8%), 2,4-pentanedione (6% ) And aromatic compound 150 (2%). Visgard® Part B components include polyisocyanate (66%), free monomer isocyanate (1%), xylene (11%), n-butyl acetate (11%), and toluene (11%). As pointed out, Visgard® Part A and Part B components are readily available. Furthermore, known films usually contain additional solvents, such as additional amounts of diacetone alcohol and tertiary butyl alcohol, in order to dilute the mixture. Moreover, known film production processes often require two separate coating steps and two curing cycles. Curing time, temperature and methodology can have a significant impact on anti-fog and anti-frost properties. For example, excessive curing will significantly reduce its properties. Forced convection, in the slowest way, can cause excessive hardening of the thin skin of the film, causing damage to anti-fog and / or anti-frost properties. Radiant energy is a fast and effective way to avoid excessive hardening.

Some suitable coatings, films, and embodiments thereof are disclosed in US Pat. Nos. 4,467,073, 5,262,475, 5,877,254, and US Patent Application Publications US2003 / 0205059 A1, US2005 / 0064101, US2005 / 0064173, and US2005 / 0100730. All of which are incorporated herein by reference. These and other patents and patent applications provided herein will be sufficient guidance to those skilled in the art to readily practice the present invention.

However, the present invention also provides new anti-fog and anti-frost coatings / films that exhibit more improved performance over the other known films described above. The present invention further provides new methods of making and applying such improved films. For example, when the ratio of the mixture of chemical Part A and Part B (described above with respect to Visgard®) is about 100 units of Part A and about 25 to 45 units of Part B, an improvement over known films We found the surprising fact that this resulted in anti-fog and anti-frost. The smaller the amount of the Part B component (functioning as a hardener) within the above range, the more the anti-frost property is improved while maintaining the scratch resistance of the film. Good antifogging properties can be achieved when the percentile of the Part B component is higher. In a preferred embodiment, the ratio is about 100 units of Part A components and about 30 to 33 units of Part B components. In a particularly preferred embodiment, the ratio is about 100 units of Part A and about 30 units of Part B.

It has also been surprisingly found that not considering the use of additional solvents such as additional diacetone alcohol and tertiary butyl alcohol (particularly additional diacetone alcohol) improves antifogging and / or anti-frosting performance. In particular, removal of such solvents improves antifogging performance. However, it has been found that the addition of one or more of these solvents (tertiary butyl alcohol) does not interfere with the anti-frosting performance. Moreover, in embodiments of the present invention, the cured primers commonly included in existing known films pre-treat the glass substrate with silane and add other silanes to the anti-fog / anti-frost mix. By removing it. For example, silane pretreatment may assist the polymer coating to adhere to the substrate under extreme chemical conditions or long term moisture absorption. In a preferred embodiment, the silane added to the mixture is 3-glycidoxypropyl trimethoxysilane. Surprisingly, it has been found that the inclusion of this silane results in improved wear resistance (ie scratch resistance) and improved adhesion and weatherability. Also, unlike some silanes, 3-glycidoxyoxy trimethoxysilane does not enhance yellowing. In a preferred embodiment, 3-glycidoxyoxy trimethoxysilane is present in an amount from about 1% to about 8%, most preferably about 6%. Other silane additives may be used for the same effect. Furthermore, other suitable additives and primers are those which can promote the adhesion of urethane to inorganic compounds such as glass. These materials include, but are not limited to, polymers having affinity for glass.

The present invention also provides new methods of making and applying such films. In one aspect, the present invention provides a method that can reduce the coating step with a single coating having a single curing cycle. Among other advantages, this reduces the chance of damage due to excessive hardening. Furthermore, in embodiments of the present invention, a curtain coater is used to provide a coating or film. Adjustments are made to prevent excessively high Reynolds numbers in the curtain to avoid semi-turbulent and vortex flow regimes. For example, in embodiments, a standard weir-type curtain coater can be adapted to provide the desired laminar flow. Such modifications may include size limitations of the weir lips to avoid anti-vortex flow regimes.

In alternative embodiments, the substrate, preferably glass, may be pretreated with silane (preferably Silquest A-1106 amino alkyl silicone) to promote wetting and adhesion. By mixing about 1% of the silane into the rinse water of the glass washer, a special silane is provided. This method eliminates some of the additional steps required by conventional known methods. Thus, some known anti-fogging and anti-frost coatings or films can be used in combination with other aspects of the invention described herein, and the present invention is also a novel anti-fogging and anti-frost coating / film improved over that seen in the prior art. , And novel methods of making and providing the same. In an embodiment, the present invention provides a coating / film that contains a modified anti-fog and anti-frost film / coating and a specific solvent commonly used in which the proportion of Part A and Part B chemicals (as mentioned above) in the mix is modified. to provide. Moreover, in embodiments of the present invention, the properties of the film can be improved by modifying the curing cycle. The substrate may also be pretreated to enhance wetting and adhesion.

Thus, in one aspect, the present invention provides a polymer composition having antifogging and anti-frosting properties upon drying or curing. In a preferred embodiment, the chemical mixing ratio of the Part A and Part B chemicals (described herein) of this composition is about 100: 30 and does not include a curing primer, solvent, or diluent provided on the glass substrate. In an alternative embodiment, the mix comprises a silane, preferably 3-glycidoxypropyl trimethoxysilane. Preferred compositions promote scratch resistance, adhesion and weather resistance.

In another aspect, the invention provides a refrigerated door made of a substantially transparent substrate having at least a portion of an anti-fog or anti-frost coating, wherein the portion has a wet surface having an initial surface temperature and then a dew point above that surface temperature. When exposed to ambient air for a period of time, substantially no steaming or frost is formed on part of the substrate. The surface temperature may be less than 0 ° C. and the time may be 6 seconds or more.

The present invention also provides a method of making a refrigerated door having a substantially transparent substrate, the method comprising forming at least a portion of the anti-fog or anti-frost coating described herein, wherein the substrate is a member of the refrigerated door or Used in the manufacture of refrigerated doors. In an embodiment, the method includes mixing Part A and Part B chemicals to form a mixture and providing the mixture to at least a portion of the substrate to cure the substrate. The invention also provides an IGU comprising a substrate having an antifogging or anti-fog coating at least in part as described herein, a refrigeration door comprising such an IGU, a refrigeration system comprising a refrigeration door. Furthermore, in a further embodiment, the present invention provides a refrigerated door, consisting of a substantially transparent substrate having a coating on at least a portion thereof, wherein the coating comprises a portion of said temperature of about -28 ° C 12 at a temperature of about 25 ° C If exposed for more than a second, prevent condensation of water on it. Prevention of condensed droplets prevents the formation of light scattering fog or frost.

In the embodiment shown in FIG. 3, the inner sheet 70 can be, for example, 1/8 inch thick Comfort Ti-PS manufactured by AFG Industries, Inc., having the above-described characteristics and coating, but not limited thereto. Does not.

In this illustrated embodiment, the chambers 92 and 94 are all filled with air. In alternative embodiments, each chamber may be filled with the same or a different gas, and the chamber may be filled with krypton, argon or other suitable gas.

The sheets 60, 65 are kept spaced apart by a first sealant assembly 90 extending around the sheets 60, 65 holding the glass sheets in parallel, and spaced apart between the sheets 60, 65. A chamber 92 that forms a relationship is formed and at the same time the chamber 92 is sealed from the external environment. Similarly, the sheets 65, 70 are spaced apart by a second sealant assembly 95 extending around the sheets 65, 70 holding the glass sheets in parallel, between the sheets 65, 70. At the same time a chamber 94 is formed which forms a spaced apart relationship and the chamber 94 is sealed from the external environment. The sealant assemblies 90, 95 maintain a gap of 1/2 inch between the outer sheet 60 and the intermediate sheet 65 and between the inner sheet 70 and the intermediate sheet 65, respectively.

The sealant assemblies 90 and 95 of this embodiment are preferably warm edge seals. "Worm edge" is used to describe an insulated glass sealing assembly that has further reduced heat loss than conventional aluminum spacer and sealant assemblies. Each sealant assembly 90, 95 of this embodiment includes its own spacers and desiccants, replacing the need for individual sealants, metal spacers and desiccants, 0.84 BTU / hr-sq ft − It has a heat transfer rate of F (often referred to as K value). The sealant assemblies 90 and 95 of this embodiment are composite extruded articles comprising polyisobutylene sealant, hot melt butyl sealant, desiccant matrix, rubber shim and water vapor walls. A suitable sealant assembly of this type is the trade name " Comfort Seal " manufactured and sold by TruSeal Technologies, Beachwood, Ohio.

IGU 50 is shown in FIG. 3. The IGU 50 is composed of glass sheets 60, 65, 70 integrated by sealant assemblies 90, 95. IGU 50 is installed in frame 55 in any suitable manner well known to those skilled in the art. Frame 55 is made of extruded plastic or other suitable frame material that is well known, such as extruded aluminum, fiber glass or other materials. In some alternative embodiments, when the frame 55 is formed of aluminum or other material, it may be necessary to heat the door along the edge to ensure condensation control around the edge of the door.

1 shows a refrigeration system 5. The door frame 55 is coupled to the refrigeration compartment 8 in a manner well known in the art, such as a single door long hinge, multiple hinges, or slots in which the door slides open and closed. In addition, the frame may comprise the door handle 11 or other suitable actuation means suitable for the application. The refrigeration system 5, in which the refrigeration door 10 forms a part, may be any system used for cooling the compartment as disclosed in US Pat. No. 6,148,563, which is incorporated herein by reference.

The preferred embodiment provides a refrigerated door having a U value (emissivity of 0.0025) of 0.16 BTU / hr-sq ft-F, which is suitable for the application of a freezer door to which the US industry performance standards defined above apply. It is known. The U value of 0.16 BTU / hr-sq ft-F allows the refrigerated door to easily meet the required performance criteria, while at the same time providing sufficient access to the outside environment through the door for vaporization of condensation formed inside the door for a reasonable time. Allow the penetration of heat. In addition, preferred embodiments provide 66% visible light transmission. In the case of the preferred embodiment, including the antifogging / antifog coating or film described, no formation of fogging or frost on the glass is observed.

As an alternative to Comfort Ti-PS glass, for example, Titania / silver based low E coated glass, similar to Comfort Ti-PS, Comfort Ti-R, Comfort Ti-AC, Comfort Ti-RTC and Comfort Ti-ACTC ( Other low E coating glass, such as all available from AFG Industries Ltd., can also be used. Another suitable type of glass is Comfort E2, which is coated with a 1/8 inch thick pyrolysis process manufactured by AFG Industries, Ltd., which is a fluorine doped tin oxide low E coated glass. Comfort E2 meets some of the less stringent performance criteria because of its high emissivity. The low E coating referred to herein is not limited to the products specifically named above, but may be any suitable low E glass including, without limitation, those described above and other sputter coating and pyrolytic coating low E glass.

The U value of the refrigeration door 10 is determined by a number of design factors including the number of glass sheets, the thickness of the sheets, the emissivity of the IGUs, the spacing between the sheets and the gases in the chamber. In the triple refrigerating door 10 of the above-described preferred embodiment, the U value of 0.16 BTU / hr-sq ft-F uses air as the gas contained in the chamber, and all sheets are 1/8 inch thick. , Separation of 1/2 inch and emissivity of 0.0025. However, each of these factors can be varied to form numerous permutations of values that can be combined to give the same U value. In addition, other applications may require smaller or larger U values, depending on environmental, cost constraints, and other requirements or considerations.

A number of computer simulations are run to determine the U values of the various IGUs used in the refrigerated door 10 within the range of each of the various design parameters combined in different permutations. The table below contains the design parameters of the various triplet IGU configurations and their calculated U values. In addition to the design parameters described in Table 1 below, each window was 1/8 inch thick and the U value of the triplet IGU, with both sides of the triplet low E coated, was calculated. The strengthening of the glass did not significantly affect the calculated performance values. Moreover, the addition of the anti-fog / frost resistant coating or film according to the invention did not have a significant effect on these values.

In each table included herein, "Ti-PS" refers to a low E coating of Comfort Ti-PS glass from AFG Industries, and "CE2" refers to a low E coating of Comfort E2 glass from AFG Industries, both of which are described above. It was. In addition, because computer simulations are incapable of considering sealant assemblies, the U values listed in the table were calculated as "center of glass" values. As a result, there is no data or design criteria of the sealant assembly in the table.

In an alternative duo embodiment of the present invention shown in FIG. 4, the IGU 50 includes an outer glass sheet 60 and an inner sheet 70, a frame 55 and a sealant assembly 90. In this duo embodiment, both the outer sheet 60 and the inner sheet 70 are 1/8 inch thick and include the same low E coating as the first embodiment above, which is a low E coating of titania-based silver. Again, the outer sheet 60 and the inner sheet 70 can be, for example, a 1/8 inch thick Comfort Ti-PS glass sheet manufactured by AFG Industries. The coated surfaces of the sheets 60, 70 are located on the side surfaces 62, 72 which form part of the chamber 92, which is the non-exposed surface of the sheet, respectively. In addition, the same sealant assembly 90 (Comfort Seal) as described above may be used to serve to provide a distance of 1/2 inch between the outer glass sheet 60 and the inner sheet 70. Again, the anti-fogging / anti-frost coating or film 75 is disposed on the exposed surface 71 of the inner sheet 70.

Table 2 below contains design parameters corresponding to multiple duplex IGUs and corresponding U value calculations. In addition to the design parameters listed in the table below, the calculations for all the duplexes were done with each window having a thickness of 1/8 inch and both sides of the duplex being low E coated. The reinforcement of the glass as well as the addition of the anti-fog coating or film described herein to the antifog / stability did not significantly affect the calculated performance values.

In an alternate embodiment, a low E coating, including pyrolysis (such as in Comfort E2), spray, and sputter coating (such as in Comfort Ti-PS), often referred to as chemical vapor deposition (CVD), is used. Any suitable kind of coating method can be used. Furthermore, these methods may be applied using well-known off-line or on-line manufacturing methods that are appropriate and suitable depending on the quantity and type of production and process. Similarly, any suitable low E coating may be applied, including silver-based or fluorinated tin oxide coatings.

Although the above embodiment includes a low E coating on the non-exposed side of both glass sheet surfaces, another embodiment of the present invention may include a low E coating provided on one or both sides of one glass sheet. Similarly, in another embodiment, the intermediate glass sheet (of the triplet embodiment) is rowed on one side (or both sides) instead of or in addition to the coating of the inner glass sheet 70 and the outer sheet 60. E coatings.

In another triplet embodiment, the inner glass sheet 70 does not include a low E coating on one side thereof. Similarly, as an alternative to the two-sheet embodiment, the low E coating may be present on only one sheet or on both sides of both sheets. In general, the number of sheets with a low E coating and the number of sides with a coating is optional in design. The total emissivity of the IGU, which, together with other factors, determines the U factor of the door, is more important than which side of the sheet is coated in terms of thermal performance. In addition, although the emissivity of embodiments described herein applied to refrigerated doors is 0.04 or less, IGUs have slightly higher emissivity than 0.04 by using high performance gases (such as krypton) to provide control of the condensate needed in some environments. You can have it.

In other embodiments, other sealant assemblies may be used, including non-metal assemblies, all foams, such as Super Spacer manufactured by Edge Tech, Inc., with a thermal conductivity of about 1.51 BTU / hr-ft-F. Another suitable sealant assembly is the ThermoPlastic Spacersystem (TPS) manufactured by Lenhardt Maschinenbau Gmbh with a thermal conductivity of about 1.73 BTU / hr-ft-F.

The separation distance in the above embodiment is 1/2 inch. However, while the preferred separation range is 5/16 to 1/2 inch, other embodiments of the invention may use a separation distance up to 3/4 inch. In addition, while the above embodiment uses reinforced 1/8 inch thick glass (except for intermediate sheets), other embodiments may use unreinforced glass or glass having a thickness other than 1/8 inch.

The design parameters of an embodiment of the present invention will depend in part on the application or intended use of the embodiment. More specifically, the external ambient temperature, internal temperature, and external ambient humidity (and associated dew point) are important factors in determining the U value required for the design, followed by the U value of the design parameters (type of glass, emissivity, sheet). Number, gas, etc.).

The left five columns of Table 3 below provide the calculated U values for various applications according to the intended use, including the external temperature, internal temperature, external humidity, and dew point calculated for each U value. . In addition, in the right three columns of Table 3, there is provided an embodiment of the present invention that provides the necessary U values.

The design parameters in Table 3 are the type of glass (1/8 inch thick), the distance between the sheets, and the gas in the chamber. In addition, the IGU of Table 3 includes a third uncoated glass sheet 1/8 inch thick, which sheet is disposed between the two glass sheets defined in the table. CE1 in Table 3 means Comfort E1, and its emissivity is 0.35, which is sold by AFG Industries.

Thus, in one aspect, the present invention provides a refrigeration door suitable for use in a refrigeration compartment, the door comprising an inner glass sheet, a refrigeration compartment comprising a first surface and a second surface disposed adjacent to the interior of the refrigeration compartment. An outer glass sheet comprising a first surface and a second surface disposed adjacent to an external environment of the intermediate glass sheet disposed between the inner glass sheet and the outer glass sheet, disposed around the inner glass sheet and the intermediate glass sheet A first sealant assembly configured to maintain the inner sheet and the intermediate sheet in a spaced apart relationship, disposed around the intermediate glass sheet and around the outer glass sheet to maintain the intermediate sheet and the outer sheet in a spaced apart relationship A second sealant assembly, a first low emissivity coating adjacent the second surface of the inner glass sheet, a second table of the outer glass sheet A second low emissivity coating adjacent to a face, wherein the inner sheet, outer sheet, intermediate sheet, first sealant assembly, second sealant assembly, and the first and second low emissivity coatings comprise the first of the outer glass sheets. 1 forming an insulated glass unit having a U value of substantially 0.2 BTU / hr-sq ft-F or less substantially preventing the formation of condensate on the first surface of the outer glass sheet without the supply of electricity to heat the surface The door also includes an anti-fog or anti-frost coating of the inner sheet surface, and a frame secured to the periphery of the insulating glass unit.

The invention also provides a refrigeration door suitable for use in a refrigeration compartment, the door having an inner glass sheet comprising a first surface and a second surface disposed adjacent to the interior of the refrigeration compartment, adjacent to the external environment of the refrigeration compartment. An outer glass sheet including a first surface and a second surface disposed so as to be interposed, an intermediate glass sheet disposed between the inner glass sheet and the outer glass sheet, a periphery of the inner glass sheet and a periphery of the intermediate glass sheet, A first sealant assembly for holding the sheet and the intermediate sheet in a spaced apart relationship, and a second sealant assembly disposed around the middle glass sheet and the outer glass sheet to maintain the intermediate sheet and the outer sheet in a spaced relationship with each other A first low emissivity coating adjacent the second surface of the inner glass sheet, a second adjacent the second surface of the outer glass sheet A low emissivity coating, wherein the inner sheet, outer sheet, intermediate sheet, first sealant assembly, second sealant assembly, and the first and second low emissivity coatings are configured to heat the first surface of the outer glass sheet. Forming an insulating glass unit having an emissivity of substantially 0.04 or less that substantially prevents the formation of condensate in said outer glass sheet without supply of electricity for said door, said door having an anti-fog or anti-frost coating of the surface of said inner sheet, and It also includes a frame fixed to the periphery of the insulating glass unit.

In an embodiment, the internal temperature of the refrigeration compartment is substantially below −20 ° F .; The temperature of the external environment is substantially above 70 ° F .; The humidity of the external environment is substantially 60% or more, and no fog or frost is formed on the inner sheet because the first surface of the outer glass sheet is substantially free of condensate.

In a further embodiment, the internal temperature of the refrigeration compartment is substantially below 0 ° F, the temperature of the external environment is substantially above 72 ° F, the humidity of the external environment is substantially above 60%, and the first surface of the outer glass sheet Since there is virtually no condensation, no frost or frost is formed on the inner sheet.

The present invention further provides a refrigeration door (and an IGU, and a refrigeration system comprising them), which has an outer surface and is suitable for use in the refrigeration compartment, which door comprises a first glass sheet, a second glass sheet, a first glass sheet. Low emissivity adjacent the surface of the first sealant assembly, the first glass sheet or the second glass sheet disposed around the second glass sheet and maintaining the first sheet and the second sheet in a spaced apart relationship; A coating, wherein the first glass sheet and the second sheet, the first sealant assembly, and the first low emissivity coating form an insulating glass unit having a U value of substantially 0.2 BTU / hr-sq ft-F or less, The door also includes an anti-fog or anti-frost coating of one surface of the sheets, and a frame secured to the periphery of the insulating glass unit.

The present invention further provides a refrigeration door (and an IGU, and a refrigeration system comprising them), which has an outer surface and is suitable for use in the refrigeration compartment, wherein the door comprises a first glass sheet, a second glass sheet, a first glass sheet. A first low emissivity coating adjacent to a surface of a first sealant assembly, a first glass sheet or a second glass sheet disposed around the second glass sheet and maintaining the first sheet and the second sheet in a spaced apart relationship Wherein the first glass sheet and the second sheet, the first sealant assembly, and the first low emissivity coating form an insulated glass unit having an emissivity of substantially less than 0.04, wherein the door is fogged on one surface of the sheets. It also includes an anti- or anti-frost coating, and a frame secured to the periphery of the insulating glass unit.

The invention also provides a method of making a refrigerated door element having an outer surface, the method comprising providing a first glass sheet; Providing a second glass sheet; Providing a first low emissivity coating proximate the surface of the first glass sheet or the second glass sheet; Disposing a second sealant assembly disposed around the first glass sheet and the second glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship; Providing an anti-fog or anti-frost coating to one of the glass sheets; The first glass sheet, the second glass sheet, and the first sealant assembly may substantially reduce the formation of condensate on the outer surface of the refrigerated door element without the supply of electricity to heat the door element. to form an insulated glass unit having a U value less than or equal to hr-sq ft-F. In an alternate embodiment, the method includes providing a third glass sheet comprising a row E coating adjacent to one or more of its surfaces; Disposing a second sealant assembly disposed around the second glass sheet and the third glass sheet to maintain the second sheet and the third sheet in a spaced apart relationship; The insulated glass unit further comprises the third glass sheet and the second sealant assembly.

The invention also provides a method of making a refrigerated door element having an outer surface, the method comprising providing a first glass sheet; Providing a second glass sheet; Providing a first low emissivity coating proximate the surface of the first glass sheet or the second glass sheet; Disposing a first sealant assembly disposed around the first glass sheet and the second glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship; Providing an anti-fog or anti-frost coating to one of the glass sheets; The first glass sheet, the second glass sheet, and the first sealant assembly are substantially less than or equal to 0.04, substantially preventing the formation of condensate on the outer surface of the refrigerated door element without supply of electricity to heat the door element. To form an insulated glass unit having emissivity. In an alternate embodiment, the method includes providing a third glass sheet comprising a row E coating adjacent to one or more of its surfaces; Disposing a second sealant assembly disposed around the second glass sheet and the third glass sheet to maintain the second sheet and the third sheet in a spaced apart relationship; The insulated glass unit further comprises the third glass sheet and the second sealant assembly.

The present invention further provides a substantially transparent insulated glass unit door for use with a refrigeration compartment having an outer surface and placed in an external environment and having an internal refrigeration compartment, the insulated glass unit door comprising: a first glass sheet; Second glass sheet; A first sealant assembly disposed around the first glass sheet and the second glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship; A first low emissivity coating adjacent the surface of the first glass sheet or the second sheet; And an anti-fog or anti-frost coating of one surface of the sheets, wherein the first glass sheet, the second glass sheet, and the first sealant assembly have an internal temperature of the refrigeration compartment substantially below 0 ° F, U value effective to substantially prevent the formation of condensate on the outer surface without the supply of electricity to heat the outer surface of the insulating glass unit when the temperature of the external environment is substantially 70 ° F. or higher and the humidity of the external environment is 60% or more. It provides an insulated glass unit having a. Alternative embodiments include a third glass sheet; And a second sealant assembly disposed around the second glass sheet and the third glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship. It may also comprise a second low emissivity coating adjacent to the second glass sheet or the third glass sheet.

In an alternative embodiment, the insulating glass unit has condensation on the outer surface when the internal temperature of the refrigeration compartment is substantially below -40 ° F, the temperature of the external environment is substantially above 80 ° F, and the humidity of the external environment is above 60%. Has a U value that substantially prevents the formation of water.

The invention further provides a refrigeration unit comprising an insulation enclosure forming a compartment, a cooling system and a door suitable for mounting in the opening of the compartment, the door having an outer surface comprising: a first glass sheet, A first sealant assembly disposed around a second glass sheet, the first glass sheet and the second glass sheet to hold the first sheet and the second sheet in a spaced apart relationship, the first or second glass sheet A first low emissivity coating adjacent to the first sheet, the second sheet, the first sealant assembly, and the first low emissivity coating to supply electricity for heating the first surface of the outer glass sheet. Without forming an insulating glass unit having a U value of substantially 0.2 BTU / hr-sq ft-F or less, substantially preventing the formation of condensate in the outer glass sheet, the door being A frame fixed to the periphery of the anti-fogging coating or gender of the root surface, and the insulating glass unit further includes. In an alternate embodiment, the door further comprises a third sealant assembly and a second sealant assembly disposed around the second glass sheet and the third glass sheet to hold the second sheet and the third sheet in a spaced apart relationship. Include.

The present invention further provides a glass door for a frozen display case, the door having a first glass panel having inner and outer surfaces, a low emissivity coating of the inner surface of the first glass panel, and a second glass panel having inner and outer surfaces. A low emissivity coating of the inner surface of the second glass panel, an intermediate glass panel between the first and second glass panels, a first spacer assembly between the first and intermediate glass panels and a second glass between the intermediate and second glass panels A panel, wherein the first and second spacer assemblies are formed from a worm edge spacer assembly, the door further extending and supporting a frame that extends and supports at least one of an anti-fog or anti-frost coating and a glass panel on one surface of the glass panel. Include. In an embodiment, the width and height of the first and second glass panels are the same.

The principles, embodiments and modes of operation of the present invention have been described so far. However, the present invention should not be construed as being limited to the above specific embodiment, but should be understood as illustrative rather than limiting. Those skilled in the art should note that modifications may be made to the embodiments without departing from the scope of the present invention.

The application of the invention has been described in the application of refrigerator or freezer doors, but other applications include vending machines, skylights, or refrigeration trucks, mirrors for cars, in particular exterior mirrors, saunas, steam rooms, shower doors, ticket windows. , Bathroom windows, bathroom mirrors, external coolers and freezers exposed to high humidity or rain, and other applications requiring anti-fog or anti-frost coatings / films. In some of these applications, condensation on the second or colder side of the glass will not be an issue because there is no glass in the door that opens for a period of time and exposes the cold glass to a more humid environment. As a result, the key to the design of the glass is cost (ie energy cost and glass and its installation cost), visible permeability, durability and other considerations.

While preferred embodiments of the present invention have been described above, these are provided by way of example and not by way of limitation. Accordingly, the breadth and scope of the present invention should not be limited by the foregoing exemplary embodiments.

Obviously, various modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced without the specific details described herein.

Claims (292)

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The method of claim 226 The antifogging or anti-fogging coating, characterized in that the mixing ratio of the first component and the second component is about 100: about 30. 226. The method of claim 226 The antifogging or anti-fog coating, characterized in that the mixture further comprises a silane. 228. The method of claim 228, Wherein said silane comprises 3-glycidoxypropyl triethoxysilane. The method of claim 229, wherein The anti-fogging or anti-fog coating, characterized in that the silane is present in an amount of about 1% to about 8%. 232. The method of claim 230, The anti-fogging or anti-glare coating, characterized in that the silane is present in an amount of about 6%. A method of forming an anti-fog or anti-frost coating on at least a portion of a substrate, the method comprising Pretreating at least a portion of the substrate with a first silane;    i) about 46% diacetone alcohol, about 4% N-methyl pyrrolidone, about 4% t-butanol, about 8% cyclohexane, about 6% 2,4-pentanedione, and about 2 A first component comprising 150% of aromatics; And    ii) preparing a mixture of a second component comprising about 66% polyisocyanate, about 1% free monomer isocyanate, about 11% xylene, about 11% n-butyl acetate, and about 11% toluene It includes;    The mixing ratio of the first component and the second component is about 100: about 30 to 33, The method comprises: Providing the mixture to the substrate; And The method of forming an anti-fog or anti-frost coating further comprising the step of curing the substrate. 232. The method of claim 232, Wherein said mixture contains no additional solvent. 232. The method of claim 232, And wherein the mixing ratio of the first component and the second component is about 100: about 30. 232. The method of claim 232, Wherein said mixture is provided in a single coating step. 232. The method of claim 232, Wherein said curing is accomplished in a single curing cycle. 238. The method of claim 232 wherein the method is Further comprising adding a second silane to the mixture, And wherein said second silane is different from said first silane. 237. The method of claim 237, And wherein said second silane comprises 3-glycidoxypropyl trimethoxysilane. 238. The method of claim 238 wherein And wherein said second silane is present in an amount of about 1% to about 8%. The method of claim 239, wherein And wherein said second silane is present in an amount of about 6%. 232. The method of claim 232, Wherein said first silane comprises amino alkyl silicone. A refrigerated door having an outer surface and suitable for use in a refrigerated compartment, wherein the refrigerated door is First glass sheet; Second glass sheet; A first sealant assembly disposed around the first glass sheet and the second glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship; A first low emissivity coating adjacent the surface of the first glass sheet or the second glass sheet; An anti-fog or anti-frost coating adjacent to the surface of one of the glass sheets, The first and second glass sheets, the first sealant assembly, and the first low emissivity coating have an insulation having a U value of substantially 0.2 BTU / hr-sq ft-F or an emissivity of substantially 0.04 or less. To form a glass unit; The door is And a frame secured to the periphery of the insulated glass unit. 245. The method of claim 242 The anti-fog or anti-frost coating comprises a polymer. 253. The method of claim 243 wherein Refrigerated door, characterized in that the polymer is hydrophilic. 245. The method of claim 242 The anti-fog or anti-frost coating comprises an optical adhesive. 245. The method of claim 245, And the adhesive comprises acrylic. 253. The method of claim 243 wherein And the polymer is cured in a polyester film. 245. The method of claim 242 The anti-fog or anti-frost coating is provided as a film on the surface of the inner sheet. 245. The method of claim 242 The anti-fog or anti-frost coating is provided as a liquid on the surface of the inner sheet. 245. The method of claim 242 The anti-fog or anti-frost coating has a thickness of about 4 mils. 245. The method of claim 242 The anti-fog or anti-frost coating is refrigerated door, characterized in that insoluble in water. 245. The method of claim 242 A refrigerated door further comprising a cured primer provided on the surface of the sheet prior to providing said anti-fog or anti-frost coating. 245. The method of claim 242 The anti-fog or anti-frost coating is: i) about 46% diacetone alcohol, about 4% N-methyl pyrrolidone, about 4% t-butanol, about 8% cyclohexane, about 6% 2,4-pentanedione, and about 2 A first component comprising 150% of aromatics; And ii) a mixture of a second component comprising about 66% polyisocyanate, about 1% free monomer isocyanate, about 11% xylene, about 11% n-butyl acetate, and about 11% toluene, And the mixing ratio of the first component and the second component is about 100: about 40. 253. The method of claim 253, A refrigeration door further comprising a solvent for dilution of the mixture. The method of claim 254, wherein Refrigerated door, characterized in that the solvent is alcohol. 255. The method of claim 255, And the alcohol is diacetone alcohol or tertiary butyl alcohol. 245. The method of claim 242 The anti-fog or anti-frost coating is: i) about 46% diacetone alcohol, about 4% N-methyl pyrrolidone, about 4% t-butanol, about 8% cyclohexane, about 6% 2,4-pentanedione, and about 2 A first component comprising 150% of aromatics; And ii) a mixture of a second component comprising about 66% polyisocyanate, about 1% free monomer isocyanate, about 11% xylene, about 11% n-butyl acetate, and about 11% toluene, The mixing ratio of the first component and the second component is about 100: about 25 ~ 45 characterized in that the refrigerated door. 245. The method of claim 242 The mixing ratio of the first component and the second component is about 100: about 30 to 33 characterized in that the refrigerated door. 245. The method of claim 242 The mixing ratio of the first component and the second component is about 100: about 30. The method of claim 257 And the sheet adjacent to the anti-fog or anti-frost coating is pretreated with a first silane and the mixture comprises a second silane different from the first silane. 260. The method of claim 260, And the second silane comprises 3-glycidoxypropyl trimethoxysilane. 260. The method of claim 260, And the second silane is present in an amount of about 1% to about 8%. 260. The method of claim 260, And the second silane is present in an amount of about 6%. 260. The method of claim 260, And the first silane comprises amino alkyl silicone. 245. The door of claim 242, wherein the door is Third glass sheet; A second sealant assembly disposed around the second glass sheet and the third glass sheet to maintain the second sheet and the third sheet in a spaced apart relationship; And the insulating glass unit further comprises the third glass sheet and the second sealant assembly. 245. The method of claim 242 The U value of the insulated glass unit is such that the internal temperature of the refrigeration compartment is substantially below 0 ° F; The temperature of the external environment is substantially greater than 72 ° F .; And when the humidity of the surrounding environment is substantially 60% or more; And the effect of substantially preventing the formation of condensate on the outer surface of the door without supply of electricity to heat the outer surface. 245. The method of claim 242 A first chamber formed by the first glass sheet, the second glass sheet and the first sealant assembly; And The refrigeration door further comprises a gas disposed in the first chamber. 245. The method of claim 242 And the first sealant assembly has a heat transfer rate of substantially less than 1.73 BTU / hr-ft-F. 245. The method of claim 242 And the first sealant assembly has a heat transfer rate of substantially less than or equal to 1.51 BTU / hr-ft-F. 245. The method of claim 242 And the first sealant assembly has a heat transfer rate of substantially 0.84 BTU / hr-ft-F or less. 272. The method of claim 267 wherein And the gas is selected from the group consisting of argon, krypton, and air. 245. The method of claim 242 And the insulating glass unit has a U value of substantially 0.16 BTU / hr-sq ft-F or less. 245. The method of claim 242 And the insulated glass unit has an emissivity of substantially less than or equal to 0.01. 245. The method of claim 242 And the insulated glass unit has an emissivity of substantially 0.0025 or less. 245. The method of claim 242 The internal temperature of the refrigeration compartment is substantially below -20 ° F .; The temperature of the external environment is substantially above 70 ° F .; The humidity of the external environment is substantially at least 60%; And the outer surface of the door is substantially free of condensate. 245. The method of claim 242 The internal temperature of the refrigeration compartment is substantially below -40 ° F .; The temperature of the external environment is substantially above 80 ° F; The humidity of the external environment is substantially at least 60%; And the outer surface of the door is substantially free of condensate. 245. The method of claim 242 And the frame is formed from a material selected from the group consisting of extruded plastic, aluminum, and fiberglass. A method of making a refrigerated door element having an outer surface, the method comprising Providing a first glass sheet; Providing a second glass sheet; Providing a first low emissivity coating proximate the surface of the first glass sheet or the second glass sheet; Disposing a first sealant assembly disposed around the first glass sheet and the second glass sheet to maintain the first sheet and the second sheet in a spaced apart relationship; Providing an anti-fog or anti-frost coating on the surface of at least one of said glass sheets; The first glass sheet, the second glass sheet, and the first sealant assembly are substantially 0.2 BTU substantially preventing the formation of condensate on the outer surface of the refrigerated door element without the supply of electricity to heat the door element. A method of making a refrigerated door element that forms an insulated glass unit having a U value of less than / hr-sq ft-F. The method of claim 278, The first glass sheet, the second glass sheet and the first sealant assembly form a first chamber, Further comprising disposing a gas in the first chamber. The method of claim 278, Providing a third glass sheet; Disposing a second sealant assembly disposed around the second glass sheet and the third glass sheet to hold the second sheet and the third sheet in a spaced apart relationship; The insulating glass unit further comprises the third glass sheet and the second sealant assembly. The method of claim 278, And wherein said first sealant assembly has a heat transfer rate of substantially less than 1.73 BTU / hr-ft-F. The method of claim 278, The thickness of the first glass sheet and the second glass sheet is substantially 1/8 inch; The distance between the first glass sheet and the second glass sheet is substantially 1/2 inch. The method of claim 278, And arranging the insulated glass unit in a door frame. 280. The method of claim 279 wherein And said gas is selected from the group consisting of argon, krypton and air. The method of claim 278, And wherein said insulated glass unit has a U value of substantially 0.16 BTU / hr-sq ft-F or less. The method of claim 278, And the insulated glass unit has an emissivity of substantially less than or equal to 0.01. The method of claim 278, And the insulated glass unit has an emissivity of substantially less than 0.0025. The method of claim 278, The low emissivity coating is selected from the group consisting of titania-based silver and fluorinated tin oxide. The method of claim 278, And wherein said low emissivity coating is provided by a method selected from the group consisting of sputter coating, pyrolysis coating and spray coating. The method of claim 278, Wherein said first sealant assembly is a composite extruded article comprising a polyisobutylene sealant, a hot melt butyl sealant, a desiccant matrix, a rubber shim and a vapor barrier. The method of claim 278, At least one of the first sealant assembly and the second sealant assembly comprises a warm edge seal. 245. The method of claim 242 And the first sealant assembly is a composite extruded article comprising a polyisobutylene sealant, a hot melt butyl sealant, a desiccant matrix, a rubber shim and a vapor wall.

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